Metal 3d Printer Desktop
Brayan Sedillo
Discover how DLP (digital light processing) 3D printing technology is enabling end-part production at scale with materials, mechanical properties, speed, and part economics similar or better to traditional manufacturing.
Introducing the new, swappable 250μm printhead that includes supporting software profiles. This enables new geometries and applications, resulting in achieving smaller parts and fine features with an improved surface.
Stackable shelving is a new feature that increases part capacity of the debinder and furnace, giving greater throughput. Increased workload volume addresses bottlenecks typical at the debind sinter stages.
17-4 Stainless Steel is a precipitation hardening steel used in a wide range of industrial applications including those with mildly corrosive environments and high-strength requirements.
H13 tool steel is hot work steel with great hot hardness, resistance to thermal fatigue cracking, and stability in heat treatment. This makes it an ideal metal for both hot and cold work tooling applications.
The Desktop Metal Studio system produces near-net-shape metal parts with the accuracy and layer resolution needed for functional prototyping and a variety of other applications. A seamless 3D printing experience, from printing through to sintering, is created with powerful software and automatic support generation.
The Desktop Metal Studio system does not require any wire EDM or machining to remove support structures. Proprietary separable supports make it possible to remove support by hand because it is no bonded to the part. As a result, highly complex parts and print-in-place assemblies can be easily printed and put to use.
The Studio Desktop Metal 3D printer extrudes bound metal rods similar to a plastic FDM system. Unlike laser-based DMLS 3D printers that selectively bond metal powders the Studio system does not require any special safety or facility requirements and creates the opportunity to produce closed-cell infill for lightweight structures as well as work with a wider range of metal alloys.
The Studio System 2 furnace is designed to be the easiest to use furnace ever made. It first heats parts to remove all binders, then increases the temperature to near-melting point to deliver industrial-strength sintering in an office-friendly package. Built-in temperature profiles tuned to every build and material ensure uniform heating and cooling without the residual stresses introduced in laser-based systems.
Stainless steel, copper, and tool steels are some of the many critical allows the Studio System brings to 3D printing. Every alloy goes through meticulous qualification by world-leading materials scientists, and our core materials consistently meet or exceed industry standards.
Ti64 for Studio System 2 produces lightweight 3D printed parts due to its high strength-to-weight ratio, thus becoming ideal for countless applications from key industries such as aerospace and defence, automotive, oil and gas, and medical.
In some cases, replacement parts are no longer available, either off the shelf or from the OEM (Original Equipment Manufacturer). Fabricating custom gears via hobbing and broaching is often expensive. With metal 3D printing, the manufacturing of such parts is possible at lower costs and reduced lead times.
Printing on the Studio System allows these channels to be designed for their function rather than their manufacturing method. This part can be produced in just a few days with very little hands-on work.
Prototype piston head for a reciprocating engine, optimized with generative design. Typically CNC machined from aluminum alloy, pistons can be time-consuming and difficult to rapidly prototype and test.
This burner tip was originally cast in the 1950s. With the Studio System, the company was able to recreate the part with properties similar to the original cast part, with no tooling cost or long lead times.
The quote for new tooling is usually in the tens of thousands of dollars. Thus, Studio System 2, a printer that was designed from the ground up for simple installation and use, allows for significant cost savings, especially when it comes to manufacturing obsolete parts at low costs and without compromising part quality.
The Studio System allows for the complex geometry of the heat exchanger to easily be printed as a single component. It would not be manufacturable as one component via CNC machining due to its thin external fins and a complex, internal helical cooling channel.
The 3D printing of the mold inserts shortens production run lead time and allows rapid iteration and refinement of zipper designs. Using a high-resolution printhead allows for smaller parts with finer features, requiring less post-processing.
BOSTON--(BUSINESS WIRE)--Desktop Metal (NYSE: DM) today announced the launch of the ExOne S-Max Flex, a scalable, large-format binder jetting system that 3D prints sand tooling, which foundries use to quickly cast complex metal designs for the aerospace, automotive, and energy industries, among others.
The S-Max Flex comes to market at a time of strong demand for castings, along with challenges finding labor. After years of contraction, the U.S. metalcasting industry is experiencing growth as a result of supply chain changes related to the COVID-19 pandemic. A recent survey released by the American Foundry Society shows that 90 percent of responding North American foundries have a positive business outlook and anticipate making capital investments in the next 12 months, including of 3D printers.
The all-new S-Max Flex prints standard silica sand with furan binders and delivers final parts with dimensional accuracy of +/- 0.5 mm. The system comes with several accessories and safety features that are configurable to fit a variety of spaces.
Binder Jetting - the Fastest AM Method for Mass Production
Binder jet 3D printing is widely regarded as the fastest additive manufacturing method for the mass production of functional precision parts. Sand binder jet 3D printing has been used in foundries for more than two decades to create metalcasting tooling cost-effectively and with low turnaround times.
Until recently, 3D printing with metal has been limited to sintering or powder 3D printing. Essentially, metal powder is bound together using high powered lasers, and then the parts are post-processed in a kiln or forge to produce nearly 100% solid metal parts. These machines, materials, and the post-processing needed to produce parts are expensive to own ($100,000+ for entry-level machines), and cost-prohibitive for the general public. You could easily spend over $1000 for a few small parts.
Fused Filament Fabrication (FFF) 3D printing has been around for a few decades now and is well established, but is generally limited to thermoplastics. Metal Injection Molding (MIM) has been around for a while as well, and is now a common manufacturing process. You have almost certainly used a tool or device recently that had MIM components in it (cordless drill, watch, car parts or even keys).
There are a few reasons you may be interested in printing with metal using a desktop 3D printer. First, if you are currently producing metal parts, prototyping through traditional milling methods, and have the need for low volume injection molded parts, consider using BASF Ultrafuse 316L 3D printing filament.
Second would be if you simply need more strength and durability compared to your plastic 3D printed parts. Transitioning to metal parts is now easier and more accessible than it ever has been by using Ultrafuse 316L on your desktop 3D printer. This material is specifically designed for manufacturers, small business owners, or anyone looking to produce metal components on a smaller scale without all the complexity of conventional CNC milling or MIM procedures.
Along with anisotropic shrinking, there are other design elements that need to be considered for succeeding with desktop metal 3D printing. These recommendations are intended to provide guidance in order to succeed early on. As expertise progresses, these rules can be adjusted for your specific designs and use cases.
If you are using MatterControl you can scale your objects pior to printing with the built in scale tool. It supports Ultrafuse 316L directly and will make your part exactly the right scale for the green part.
Send to Sintering and Debinding Service House - There are service houses that are set up with all the proper tools and materials to succeed with Metal Injection Molding, debinding, and sintering. Simply print and clean your part, mail it off, and wait for it to return in just a few days after a scheduled run.
In-house - Access the proper debinding and sintering industrial-level equipment and materials, which can cost up to a fortune for professionals just getting into additive metal manufacturing. Successfully operating these machines will require proper knowledge and particular skill sets.
If you, your business, or manufacturing process is looking to rapidly create prototype or production metal parts without spending the traditional time and cost of machining expensive consumables, then desktop 3D printing with BASF Ultrafuse 316L Metal 3D Printing Filament is the best choice for you. Using this material on a standard desktop 3D printer is a cost-effective alternative to typical subtractive methods or setup and tooling costs of metal injection molding.
As 3D printing becomes more widely available to the average consumer, its capabilities and possibilities also expand. Attainable industrial materials on the market such as the BASF Ultrafuse 316L Metal 3D Printing Filament make 3D printing metal more affordable and easier for any maker passionate about advanced prototyping. When engineering-grade plastics such as NylonX and NylonG have satisfied the early rounds of designing and testing a project, makers can then move on to producing metal parts for an even more advanced 3D printing experience. Do more with your time and creativity when you dive into the world of 3D printing metal.
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